Water barrier for footwear

ABSTRACT

A footwear construction including a barrier element that restricts the transfer of water into the footwear. The footwear can include an upper joined with a sole, with at least one of the upper and sole defining a channel that allows air to circulate to the upper. The barrier element can be located in the channel, and can include a phase change material that swells to close the channel when subjected to water. The barrier element can act as a valve to restrict the flow of water into the upper through the channel when subjected to water. The barrier element can be water absorbing polymer included in a non-woven sheet. When dry, the barrier element can allow air to pass through the channel and circulate to an interior of the upper. The barrier element can be wetted and dried repeatedly, yet still function to restrict water flow into the footwear.

BACKGROUND OF THE INVENTION

The present invention relates to footwear, and more particularly tofootwear for outdoor use.

Outdoor footwear products are typically designed to provide, among otherthings, comfort in a variety of environmental conditions. For example,most outdoor footwear is designed to keep feet dry when exposed to wetor damp conditions, such as that encountered when a wearer traverseswater, or engages in activity in rain or snow. If not addressed, suchconditions can quickly saturate the footwear with water, possiblycausing discomfort, blisters, and bacteria growth if not controlled.

Many manufacturers waterproof outdoor footwear to prevent water fromentering the footwear and causing the above issues. While this techniqueworks in some cases, it can create additional issues. For example, ifthe wearer steps in water deeper than the height of the footwear, waterwill fill the waterproof footwear. Water also may enter waterprooffootwear by running down the wearer's leg into the footwear. After waterenters waterproof footwear, the waterproofing features typically preventwater from exiting the footwear and drying out, thereby increasingdiscomfort for the wearer. Further, the waterproofing features of mostwaterproof footwear significantly reduce air circulation. In such cases,waterproof footwear can cause excessive perspiration, and can actuallycontribute to wetness or perspiration build-up within the footwear.

While many manufacturers have attempted to provide waterproof footwearwith a variety of constructions, there still remains room forimprovement.

SUMMARY OF THE INVENTION

A footwear construction is provided including a system that managesfootwear air circulation, as well as moisture and/or water infiltration.

In one embodiment, the footwear includes a barrier element thatrestricts the transfer of water into the footwear. The footwear caninclude a channel leading from an exterior of the footwear to aninterior of the footwear. When contacted with water or other liquid, thebarrier element can close at least a portion of the channel to restrictthe flow of water or other liquid from the exterior of the footwear tothe interior of the footwear, thereby providing a water barrier.

In another embodiment, the footwear can include an upper joined with asole, with at least one of the upper and sole defining the channel. Thechannel allows air to circulate to the upper. The barrier element can belocated in the channel, and can include a phase change material thatwhen wet, swells to close the channel. Optionally, the barrier elementcan act as a valve to restrict the flow of water into the upper throughthe channel when subjected to water.

In yet another embodiment, the barrier element can include a waterabsorbing polymer included in a non-woven sheet. When dry, the barrierelement can allow air to pass through the channel and circulate to aninterior of the upper. When wet, the barrier element can change indimension, and in so doing, can close at least a portion of the channelto restrict water flow into the footwear. Optionally, the barrierelement can be wetted and dried repeatedly, yet still function torestrict water flow into the footwear when wet.

In still another embodiment, the sole can include a midsole and anoutsole. The channel can be defined in the midsole, and can extend froman exterior of the footwear to an interior of the upper. The barrierelement can be at least partially positioned in the channel, and canundergo a phase change to at least partially close the channel whenexposed to water, thereby restricting a flow of water from the exteriorof the footwear to the interior of the upper.

In a further embodiment, the upper of the footwear can include awaterproof membrane. The waterproof membrane can define an opening influid communication with the channel that leads to the exterior of thefootwear. The opening optionally can be located on the bottom of theupper, adjacent the sole. The barrier element can enable air tocirculate through the channel and the opening when dry, yet restrictwater from passing through the channel and opening when the barrierelement is wet.

In yet a further embodiment, a secondary element including a base and amesh screen can be included in the channel between the barrier elementand the exterior of the footwear. The screen can prevent dirt or debrisfrom clogging the exit of the channel to the environment.

In still a further embodiment, the barrier element can be locatedadjacent the secondary element with a gap formed at least partiallytherebetween. The mesh screen can allow water to pass through the meshscreen to contact the barrier element. The barrier element can swellwhen contacted with the water that passes through the mesh screen to atleast partially close the gap.

In another further embodiment, the footwear can include a sealingelement joined with a barrier element. The sealing element can belocated adjacent a portion of the channel, for example, a hole in thesole, that is in fluid communication with the interior of the footwear.The sealing element can be aligned with the hole so that it closes thehole when the barrier element expands, thereby restricting water fromflowing into the hole and further into the footwear interior.

The footwear construction herein provides improved ventilation in dryenvironments, and also provides a substantial barrier to waterinfiltration in wet environments. The barrier element can be included inchannels that provide air flow to the interior of the footwear. Thebarrier element, when dry, can facilitate the exchange of air betweenthe interior of the upper and the exterior of the footwear via thechannels. This provides a somewhat open and breathable structure for thefootwear. The barrier element, when wet, can expand in dimension and/orswell to close the channels leading from the footwear exterior to theinterior. Optionally, the barrier element can undergo a physicaltransformation to restrict water from passing through the barrierelement. In turn, this can restrict the passage of water into the upper.

These and other features and advantages of the present invention willbecome apparent from the following description of the invention, whenviewed in accordance with the accompanying drawings and appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is side view of a footwear construction of a current embodiment;

FIG. 2 is an exploded perspective view of the footwear;

FIG. 3 is a top view of a sole of the footwear;

FIG. 4 is a section view of the footwear taken along line 4-4 of FIG. 1when dry;

FIG. 5 is a second section view of the footwear taken along line 4-4 ofFIG. 1 when the footwear is subjected to water;

FIG. 6 is a section view of the footwear taken along line 6-6 of FIG. 1when dry;

FIG. 7 is a close up view of a barrier element in the footwear shown inFIG. 6 when dry;

FIG. 8 is a second section view of the footwear taken along line 6-6 ofFIG. 1 when the footwear is subjected to water;

FIG. 9 is a close up view of a barrier element in the footwear shown inFIG. 4 when the footwear is subjected to water;

FIG. 10 is a section view of a first alternative embodiment of thefootwear taken along line 6-6 of FIG. 1;

FIG. 11 is a section view of a second alternative embodiment of thefootwear taken along line 6-6 of FIG. 1;

FIG. 12 is a section view of a third alternative embodiment of thefootwear taken along line 6-6 of FIG. 1;

FIG. 13 is a section view of a fourth alternative embodiment of thefootwear taken along line 6-6 of FIG. 1 when dry; and

FIG. 14 is a section view of the fourth alternative embodiment of thefootwear taken along line 6-6 of FIG. 1 when the footwear is subjectedto water.

DETAILED DESCRIPTION OF THE CURRENT EMBODIMENTS I. Overview

A boot incorporating the construction of a current embodiment is shownin FIGS. 1-9 and generally designated 10. For purposes of thedisclosure, the embodiment is described in connection with athree-quarter height boot, however, the construction is well suited foruse with other types of soled footwear. In general, the boot includes anupper 20 joined with a sole 90, which can include an outsole 40 and amidsole 30. The midsole 30 can include a heel wedge 50 located in theheel region 44 of the boot 10. The midsole 30 also can include channels60 that extend from an exterior 110 of the footwear to an interior 120of the upper 20. These channels 60 can provide fluid communicationbetween the exterior 110 and interior 120. This fluid communication canprovide air flow in to and out from the upper, which in turn can provideimproved ventilation to a user's foot when positioned in the footwear10.

At least one barrier element 70 is in fluid communication with thechannels 60. The barrier element 70 can be constructed from a variety ofmaterials that undergo a transformation or a phase change that in somemanner closes off at least a portion of the one or more channels 60 torestrict water flow from an exterior 110 of the footwear to the interior120 of the footwear when subjected to water. When dry, the barrierelement 70 also allows air to circulate between the interior 120 and theexterior 110, as described in more detail below. In general, the barrierelement 70 provides the relatively open and breathable structure whendry, which allows ample ventilation to the wearer's foot. The barrierelement, however, becomes substantially impassable by water when wet,and generally closes a substantial portion of the channel to preventwater from flowing through it.

It is also noted that while the barrier element 70 is primarilyillustrated as being utilized in the sole 80 of the footwear, forexample, in the midsole 30, the barrier element 70 can also be utilizedin the outsole and/or upper 120 as desired.

As used herein, the term “arch region” refers generally to a portion ofthe shoe corresponding to the arch of the wearer's foot; the term“forefoot region” refers generally to a portion of the foot forward ofthe arch region corresponding to the forefoot (for example, the ball andtoes) of a wearer's foot; and the term “heel region” refers generally tothat portion of the shoe rearward of the arch region corresponding tothe heel of the wearer's foot. The forefoot region 42, arch region 43,and heel region 44 are generally identified in FIG. 1; however, thedelineation of these regions may vary depending on the configuration ofthe footwear.

II. Construction

Referring to FIGS. 1-9, the components of the footwear 10 will now bedescribed in more detail, beginning with the upper 20. The upper 20 canbe generally conventional, and can include a vamp 22, quarters 24, and abackstay 26. Optionally, a removable footbed (not shown) can bepositioned inside the upper 20 as desired. With reference to FIGS. 2 and4, the upper 20 includes a lower portion that transitions to anallowance 23, also referred to as a peripheral allowance, which isfolded inward toward the center of the footwear 23. The footwear 23 canbe lasted to a sole board (not shown) or Stroebel stitched to an insole25 and/or a fabric sock liner. The insole 25 can be generally flexible,and can be cemented, stitched, stapled, or otherwise fastened to theupper, and in particular, the peripheral allowance 23. The insole 25 canbe constructed from a variety of conventional materials.

As shown in FIG. 2, the insole 25 can define one or more holes orapertures 26. These apertures 26 can be defined in different portions ofthe insole 25, for example, in the forefoot region 42 and in the heelregion 44, or in other combinations of regions as desired. Althoughshown as being separate, the holes 26 can be a continuous single holeextending from the heel region 44 to the forefoot region 42. The holes26 can extend both through the material of the upper 20, as well as anyinternal liners (discussed below) used in the upper 20.

The sole 90 can extend upwardly along the sides of the upper asufficient distance to cover the holes 26 in the bottom of the footwear.Sufficient cement and/or adhesives can also be utilized to act as awater barrier to prevent water from leaking between the upper and themidsole, where they are joined together into the holes 26, and causingwater infiltration at that location. Further optionally, althoughillustrated as elongate holes, the apertures 26 can be a series ofsmaller slits or holes.

As shown in FIG. 2, a mesh 27 can extend across the respective holes 26.The mesh can be formed from canvas, nylon, metal or polymeric screens,or open pore fabrics or cloth or other synthetic materials. The mesh canbe an open, breathable construction that allows moisture and air tofreely pass through it with minimal restriction. The mesh can be joinedwith the adjacent portion of the insole 25 in a variety of manners, forexample, by stitching, cementing, or otherwise fastening the mesh to thematerial surrounding the respective hole 26. Optionally, inconstructions where the insole 25 has sufficient integrity, the mesh canbe removed. Further optionally, the insole 25 can be constructed from abreathable, circulation promoting material and the holes 26 andassociated mesh 27 can both be absent.

In the embodiment shown in FIG. 2, the mesh 27 in the openings 26 isgenerally aligned with respective channel 60 in the heel 44 and forefoot42 regions of the footwear 10 so that air passing from the exterior 110of the footwear to the interior of the footwear 120 passes through thechannels, as well as the openings 26 and mesh 27, respectively.

As illustrated in FIG. 4, the mesh 27 can be aligned with the holes 39defined in the midsole 30, which again are further aligned with, andoptionally form a part of the channels 60. In such a configuration, airflow indicated by arrows 113 and 115 can flow into and out from theinterior 120 of the footwear in dry conditions.

The footwear 10 also can include a liner 28, also referred to as awaterproof membrane herein. The liner 28 can extend downwardly andterminate adjacent the hole 26 at a periphery 29. With such aconstruction, air can circulate from the interior 120 of the upperthrough the hole 26 and optionally out the channels 60 to the exterior110 of the footwear. The liner also can extend upwardly to the top ofthe upper, terminating a second opening that fits around the neck of theankle of a wearer.

In general, the liner or waterproof membrane 29 restricts water fromentering the interior of the upper. The waterproof membrane 28 can beconstructed from any material, but in the embodiment illustrated, isconstructed from a water-impermeable fabric or material. Suitablematerials for use to form the waterproof membrane include materials soldunder the trademark Gore-Tex, which is commercially available from W.L.Gore & Associates, Inc., of Newark, Del., as well as materials soldunder the trademark SYMPATEX, which is commercially available fromSympaTex Technologies GmbH of Wuppertal, Germany. Optionally, thewaterproof membrane can be constructed from a continuous layer ofwaterproof thermoplastic or adhesive, which coats the interior of theupper, or further optionally constructed from a polyurethane membrane orlatex seam seal construction. Regardless of the materials used, all ofthe foregoing can be considered to form a waterproof membrane as usedherein. Furthermore, although certain materials are not considered to becompletely waterproof, that is, they are water resistant or generallyform water barriers, they may also be used to construct the waterproofmembrane of the footwear 10.

The outsole 40 can be manufactured from a relatively hard rubber orother sufficiently durable or wear-resistant material. The bottom 46 caninclude an outer surface 48 that forms the wearing surface of theoutsole 40, and can be contoured to the desired heel and trim pattern.The outer surface 48 can be textured to provide traction from the heelto the forefoot if desired. Optionally, the upper surface 47 can becontoured to form portions of the respective channels 60.

As shown in FIGS. 1-5, the midsole 30 of the sole 90 can extend from theheel region 44 to the forefoot region 42, and can be formed as a single,unitary and integral structure. The midsole 30 can include one or morechannels 60 extending from the exterior 110 of the footwear inwardlythrough the midsole 30. These channels 60 can define openings 61 in theexterior visible surface 31 of the midsole as shown in FIGS. 1 and 2.The openings 61 can transition to elongate portions 63 of the channel60.

The channels can be formed in part by the midsole 30, as well as theupper surface 47 of the outsole 40. For example, the channels 60 can bedefined partially by the midsole 30, while a bottom wall of the channelis defined by the upper surface 47 of the outsole. It is noted here thatthe outsole 40 can be adhered or cemented directly to the midsole 30 inthe current embodiment. Of course, the midsole and outsole can be of aintegral monolithic structure that is alternatively direct attached tothe upper 20 in other applications. The midsole can be constructed froma variety of materials, such as polyurethane, ethyl vinyl acetate, orany other conventional material.

Returning to FIG. 2, the channels 60 can be defined in both the upper 33and lower 32 surfaces of the midsole 30. If desired, the midsole 30 caninclude multiple lower channels 64 and upper channels 65 that generallyintersect one another as described in U.S. Pat. No. 6,701,640 to Nakano,which is hereby incorporated by reference in its entirety. The upperchannels and lower channels can intersect at openings 66 tocooperatively provide fluid flow paths vertically through the midsole. Anumber of the channels 60 in the forefoot are open to the environmentvia the openings 61. The channels 68 shown in FIG. 3 running lengthwisealong the midsole 30 can generally connect the channels 60 in theforefoot region and the heel region. Other channel structures can besubstituted as desired. For example, the sole 90 can simply includeopen-ended tube-shaped apertures that open to the exterior 110 throughthe outsole 40 or through side 31 of the midsole 30, and extend upwardlyto the upper surface 33 of the midsole 30 so that they are in fluidcommunication with the holes 26 and/or interior 120 of the upper.

With reference to FIG. 3, a shank 81 can be joined with or moldedintegrally with the midsole 30 or other component of the footwear asdesired. The shank can be positioned at least partially in the archregion 43 and/or the heel region 44 of the footwear, and can beconstructed of metal, plastic, or other conventional shank materials.

With reference to FIG. 2, in the forefoot region 42 of the footwear, themidsole 30 can define grooves 36 which extend generally lengthwise alongthe sole 90. These grooves 36 can be generally transverse to and canintersect one or more of the channels 60. The depth of the grooves 60can be slightly greater than the vertical depth of the channels. Thegrooves can be located between the exterior 110 of the footwear and/orthe openings 66 that provide fluid communication between the lowerchannels 64 and the upper channels 65, which collectively form a part ofthe channels 60. Optionally, the grooves 36 can be located between theopening 61 to the holes 26 that lead to the interior 120 of the upper.The grooves 36 can be reproduced on the both the medial and lateralsides of the footwear or wherever the channels 60 open to the exteriorof the footwear.

FIG. 4 illustrates a cross section of the groove 36 in the forefootregion and its intersection with the channels 60. In general, the groove36 is adapted to receive a barrier element 70. Accordingly, it can beslightly larger than the barrier element 70 so that the barrier element70 can fit within it.

Referring to FIG. 2, the sole 90 can include a heel wedge 50. The heelwedge optionally can be constructed from a different density ordurometer material from the midsole. The heel wedge 50 can be fittedinto the heel region within a cavity 37 defined by the under surface 32of the midsole 30. The heel wedge itself can define multiple subchannels52 that extend laterally across it. These wedge subchannels 52 are openso that they fluidly communicate with the corresponding channels 60defined in the heel region of the footwear, which themselves aregenerally defined in the bottom surface 32 of the midsole.

The heel wedge 50 can include multiple additional components and take ona variety of configurations. For example, as illustrated in FIGS. 2 and3, it can include a lateral shoulder 55 extending generally away fromthe heel wedge lateral sidewall 57. In general, these two components,the lateral shoulder 55 and the lateral sidewall 57, can function toform a portion of groove 36 that is transversely oriented relative toone or more channels 60 in the heel region as explained in furtherdetail below.

As shown in FIGS. 2 and 6, the sole 90 can include barrier elements 70.These barrier elements 70 can be disposed and the heel and forefootregions as illustrated, or any combination of the heel, forefoot andarch regions, depending on the particular footwear and activity in whichthe footwear is to be used. The barrier elements 70 can be constructedof any material or composition which, when dry allows air to passthrough and/or around it, but when wet, restricts the flow of waterthrough it and/or around it. Optionally, the barrier element can beconstructed from a material or composition which is of a first dimensionand generally configured in a reduced mode, when dry. When subjected towater or other liquids, however, the barrier element swells and/orincreases in dimension to a swelled mode. When placed in a tight fittingarea, the barrier element can swell sufficiently to close gaps orregions between it and immediately adjacent surfaces so that water orliquids are restricted from passing between the barrier element andthose surfaces. In the swelled mode, the barrier element also optionallycan close off internal passageways to restrict water from flowingthrough the element. As used herein, restricting a flow of water orliquid generally means that the flow of water can be completely orpartially prevented from passing around and/or through a structure orspace.

Explained in another way, the structure of the barrier element 70 can besuch that when it is contacted with water, the water absorbent material(described below) included within it, increases in dimension as itabsorbs liquids, and in general, acts as a valve to restrict the flow ofwater into the upper through the channels when the footwear is subjectedto water. For example, the water absorbent material can undergo a volumechange and swells or expands. This can cause the overall dimensions ofthe barrier element to increase. Where the barrier element is placed inclose proximity to adjacent components, with relatively small gapsbetween it and the adjacent components, the swelling causes the barrierelement to protrude and project further into those gaps, therebygenerally causing them to close. Where the gaps form a portion ofchannels, the water in the channels can be prevented from moving throughthe gaps.

Further, or alternatively, the barrier element can be constructed sothat when dry, air is enabled to circulate directly through the barrierelement from a first surface to a second opposing surface on the otherside of the barrier element. When subjected to liquid, such as water,the water absorbent polymers, as noted above, swell. This swellingcauses the closure of the passage ways between the water absorbentpolymers and the fabric or other material within which the waterabsorbent polymer is embedded. In turn, the closure of the smallpassageways also further restricts water from passing through thebarrier element 70.

The barrier element 70 can include a non-woven material including awater absorbent polymer that expands in size when exposed to water. Onesuch material is referred to as a water expandable non-woven cloth,which is available from Kyowa Rubber Co. Ltd. of Hirakata City, Osaka,Japan. As illustrated in the close up of the non-woven material in FIG.7, the material can generally include multiple, closely packed fibers 71joined with one another, like a felt, with the water absorbing polymers72 included within and intermixed among and/or on the fibers. The fiberscan be in a fabric form, configured in a web, which can be single ormulti-layered, and can include any number of woven or non-woven fibrouswebs, including, but not limited to a spun-bound web, an air laid web,and/or a hydro-entangled fibrous web. Further, the fabric can be made upof one or kinds of fibers. The web may contain cotton, reconstitutedcellulose fibers, polyester fibers or melt-blown polypropylene fibers incombination with other materials, for example, wood pulp, wood cellulosefibers, and/or lightly bonded melt-blown synthetic fibers.

The water absorbent polymers or materials suitable with the footwear 10include super absorbent polymers that are capable of absorbing severaltimes their own weight of water or aqueous liquids. Some suitable superabsorbent polymers can include carboxyl-related polymers that are crosslinked by metal ions or organic cross-linking agents when heated anddried on the base web or fabric. The super absorbent polymers can bejoined or bonded with the fibers, web or fabric using a suitablemanufacturing techniques, for example, those provided in U.S. Pat. No.5,071,681 to Manning and U.S. Pat. No. 5,451,219 to Suzuki, both ofwhich are incorporated by reference in their entirety.

As shown in FIG. 2, the barrier element can be provided in sheets orstrips to fit within the grooves 36 and optionally traverse multiplechannels 60 so that multiple independent barrier elements 70 need not beplaced in each individual channel. If desired, however, the barrierelements can be constructed as multiple independent pieces andconfigured to fit within each individual channel 60.

Although shown as being positioned relatively near the opening 61 of thechannels 60, the barrier element 70 can be positioned further inwardwithin the channels. Further, the channels 60 themselves can include avariety of structures that are interconnected. In general, as usedherein, a channel can include any number of connected elements thatgenerally provide collective fluid and/or liquid communication betweenthe exterior 110 of the footwear and the interior 120 of the upper.

As shown in FIGS. 2, 3 and 7, the barrier element 70 in the heel regioncan be generally positioned in close proximity to the heel wedge 50.Optionally, the heel wedge 50 can form at least a portion of the grooves36 of the midsole 30. For example, the grooves 36 in the heel regionadjacent the heel wedge 50 can be bounded by the heel wedge lateralshoulder 55 and a heel wedge sidewall 57. In addition, the groove 36 canalso be bounded by a portion of the midsole cavity 37, as well as asecondary element 80. Generally speaking, the groove 36 in the heel canbe bounded by multiple components, for example, the bottom-most portionof the midsole cavity 37, the sidewall 57 of the heel wedge, as well asa lower shoulder 55 of the heel wedge, in addition to the secondaryelement 80. Of course, if desired, the groove 36 could be defined byonly one, or select ones of these components where included.

The footwear can include multiple secondary elements 80 located at leastpartially in the channels 60, in the forefoot, arch and/or heel regionsof the footwear. The secondary elements 80 can be positioned at leastpartially within the groove 36 defined by the midsole and transverse atleast a portion of one or more channels 60 defined with a midsole.Secondary elements 80, as shown in FIGS. 2, 6 and 7, can include a base82 defining one or more apertures or holes 84. The apertures 84generally can be aligned with the channels 60 in the forefoot and heelregions of the footwear. The secondary elements 80 can also include amesh 86 positioned within the holes 24. The mesh 60 can generally extendacross the entire openings or at least a portion of the openings. Thismesh can be any of the types of mesh explained above.

In general, the mesh 86 is aligned with the barrier element 80 withinthe channel 60. When the footwear is subjected to water, the mesh is ofa sufficient size to allow water to pass through it to contact thebarrier element and initiate a physical transformation of the barrierelement in which it swells to restrict water from flowing through and/oraround it.

The mesh 86 can be in the form of a screen that restricts mud and othersolids or debris from passing into the sole 90 through openings 61,farther into the channels 60 toward the interior 120 of the footwear 10.The mesh optionally can be molded over by the material from which thebase 82 is constructed. The base 82 can generally be a molded plastic orcomposite or other substrate that is molded directly over the mesh 86 tojoin the mesh and the base. Alternatively, the mesh can be glued,cemented or otherwise fastened to the base. Of course, if desired, thebase 82 and mesh 86 can be completely separate elements simply placedadjacent one another.

As shown in FIGS. 2 and 4, the barrier element 70 can be placed adjacentthe base 82, and in general, the secondary element 80. Both of thesecomponents can be configured so that they fit side-by-side one anotherin the groove 36. The components also can be joined with one another viaspot gluing or other joining techniques. Where spot glued, thecomponents can still enable air to flow between them relatively freely.Thus, spot gluing does not form an air-impervious glue barrier aroundthe respective channels. Of course, where water or air permeable glue isused, or in circumstances where the barrier element is very porous,allowing sufficient air flow through it, a continuous bead of glue canbe utilized. If the construction does not utilize the secondary element80, the barrier element 70 can be spot glued directly to the midsole orattached via other fasteners or cement or bonding devices to the midsole30. Alternatively, the barrier element 70 and/or the secondary element80 can be loosely positioned within the groove 36 defined by themidsole, and held there simply by virtue of it being entrapped withinthe groove when the outsole 40 is joined with the midsole 30.

As shown in FIGS. 4 and 7, the barrier element 70 can be positionedwithin the groove so that gaps 77 and 78 are established between thebarrier element 80 and the remainder of the midsole 30 and/or secondaryelement 80 and/or heel wedge 50. In general, the gaps between thebarrier element 80 and other components of the footwear 10 can bevariable in dimension. For example, when the barrier element 70 isrelatively dry, that is, it has not been recently subjected to water ormoisture, the gaps 77 and 78 achieve their greatest dimensions. When thebarrier element 70 is subjected to water, it swells and optionallychanges dimensions so that the gaps 77 and 78 achieve their smallestdimensions. In many cases, the smallest dimensions of the gaps are smallenough that water cannot easily pass or flow through them.

The gaps 77 and 78 generally can form a part of the channel 60. Incooperation with the other portions of the channels 60, when dry, thegaps enable air to circulate to the interior 120 of the upper from theexterior or environment 110 of the footwear. Although the various gaps77 and 78 are illustrated as being relatively open, given the structureof some embodiments of the barrier element, the fibers 71 (whereincluded) of the barrier element 70 can project into the gaps, and insome cases touch adjacent components, such as, the secondary element,the heel wedge, or other midsole components. Despite having the fibers71 or other structures projecting into them, these spaces 77 and 78 arestill considered gaps for purposes of this disclosure.

III. Operation and Manufacture

The operation of a current embodiment of the footwear 10 will now bedescribed. In general, the footwear 10 is adapted to provide a systemthat manages air circulation as well as moisture and/or waterinfiltration into the footwear. As shown in FIGS. 1-3, the channels 60open to the exterior 110. The channels, although formed from a varietyof different components and compartments, are in fluid communicationwith the interior of the upper 120. The channels, however, are also influid communication with one or more barrier elements 70. The barrierelements 70 can be at least partially positioned within the channels 60.In a normal dry environment, where the exterior of the footwear isgenerally dry as shown in FIGS. 4 and 7, the barrier elements 70 can beconfigured so that air can travel freely through the barrier 70 as wellas around the barrier, through the gaps 77 and 78 located between thebarrier and other components of the footwear. The air can travel in andout of the footwear to provide improved circulation to the wearer's footwithin the interior 120 of the footwear.

For example, as shown in FIGS. 6 and 7, air flows through the channels60 as illustrated by the various arrows. The barrier element 70 allowsthe air to flow in to and out from the interior 120 directly through thebarrier element and/or around the barrier element, through the gaps 77and 78 adjacent the barrier element.

The construction of the footwear in the heel region 44 can also beconfigured so that it enhances air circulation. As shown in FIG. 6, whena user exerts force on the top plate 34 of the midsole 30, for example,when the wearer's heel strikes the heel plate 34 in the direction ofarrow 158, the heel plate 34 can deflect slightly, as shown in phantomlines. In turn, this causes air to exhaust from the interior 120 of thefootwear as well as the chambers 35 of the midsole and/or heel wedge 50.When the wearer continues their stride, and the heel is drawn off theheel plate 34 in the direction of the arrow 156, air is rapidly drawninto the interior 120 of the footwear, around and/or through the barrierelement 70. This can provide increased air circulation. In general, whenthe barrier element is dry, it is relatively “open.” Accordingly, aircan pass relatively easily through and/or around it, within thechannels, providing a high degree of ventilation. When in thisrelatively dry form, the barrier element is generally referred to asbeing configured in its reduced mode.

The barrier element 70 undergoes a phase change or transformation whenit becomes wetted with liquid, such as water. As a result, the barrierelement 70 functions to restrict water flow into the interior 120 of theupper. In turn, this can provide a highly efficient water barrier. Ingeneral, when the barrier element becomes wet, the water absorbentpolymers or other material within it absorb water and begin tophysically swell. As the swelling continues, the internal passageways ofthe barrier element become substantially closed and/or constructed. Thebarrier element 70 also swells against other components of the footwearto effectively close off gaps 77, 78, or other gaps, that werepreviously adjacent the barrier element that allowed air to circulate byor around the barrier element. With the constriction or closure of theinternal passageways and gaps adjacent the barrier element, the barrierelement provides a barrier to the flow of water through the channel 60and into the interior 120 of the footwear. Where the waterproof membrane28 is included, that membrane provides waterproofing to the upper 20above the sole 90.

Depending on the particular material used to construct the barrierelement 70, the barrier element may or may not prevent all liquidsand/or water from passing through it or around it and into the interiorof the footwear. Optionally, it at least restricts water flow so thatthe interior of the footwear 120 is not substantially wetted from waterpassing completely through the channel 60 into the interior 120.

More specific examples of the operation of the footwear are shown inFIGS. 4 and 5. In FIG. 4, the footwear is in a dry environment werewater has not contacted the barrier element 70. Accordingly, aircontinues to circulate around the barrier element 70. However, as shownin FIG. 5, when water or liquid from the footwear 10 is subjected towater or liquid on its exterior 110, the water travels into the channels60 and engages and contacts the barrier element 70. The barrier element70 swells and expands to at least partially close the former gaps 77, 78around the barrier element 70. The internal passageways of the barrierelement 70 are also at least partially closed. In turn, the barrierelement acts as a water barrier to restrict the flow of water throughthe channels 60 into the interior 120 of the footwear.

Referring to FIGS. 6 and 8, the operation of the water barrier in theheel is generally illustrated. Again, FIG. 6 illustrates free movementand flow of air to and from the interior and exterior 110 and 120 in adry environment. When the footwear 10 is subjected to water as shown inFIG. 8, the barrier element 70 swells or expands in dimension from itsreduced mode to its expanded mode. In so doing, it closes off thechannel 60 so that the water is restricted from passing through thechannel 60 from the exterior 110 to the interior 120. While the barrierelement is subjected to water, it maintains its transformed state sothat it continues to restrict water from entering the interior 120 ofthe footwear through the channel 60.

After the footwear 10 is removed from the wet environment, that is, itis no longer subjected to water, the barrier element 70 can begin dryingout. As it does, it transforms from its swelled mode back to its reducedmode and in so doing, reduces in dimension. This in turn causes thevarious gaps 77, 78 around the barrier elements to reopen to an aircirculating configuration. Additionally, where included, the internalpassageways that extend generally through the barrier element 70 reopenso that air can begin to circulate through the barrier element as well.In this manner, the barrier element is able to regenerate itself toprovide air circulation again after it dries out. However, when itbecomes wet again or subject to water, it will again restrict the flowof water from the environment 110 into the interior 120 of the footwear10.

The manufacture of the footwear will now be described with reference toFIGS. 1-4. In general, the upper 20 is manufactured using conventionaltechniques and apparatus. For example, the desired upper material (notshown) can be cut to form the upper 20. The multiple elements of theupper 20 such as the vamp 22, quarters 24 and back stay 26 are fittedand sewn together. The optional waterproof membrane or liner 28 can besecured within the upper via adhesives or stitching that does notdeteriorate the water impermeability of the membrane or liner in thedesired areas. The liner 28 can also be fitted to the upper so that inthe finished footwear 10 it extends downward a sufficient distance sothat the later-added midsole 30 terminates above the lowermost portionof the liner.

The peripheral allowance 23 can be Stroebel stitched or otherwiseattached to the insole 28. The insole 28 can be prefinished to includeholes 26 and the respective mesh 27 within the holes. The outsole 40,midsole 30 and heel wedge 50 can be manufactured including the featuresdescribed above. These components can be injection molded or porermolded from the respective materials as discussed above.

With the midsole manufactured, it can be outfitted with strips of thebarrier elements 70 disposed within the respective grooves 36. Ifutilized, the secondary element 80 including the base 84 and mesh 86 canbe included in the grooves 36, generally between the barrier element andthe opening 61 of the channel 60. If desired, the secondary element 80can be glued within the groove. The barrier element 70 also can be spotglued within the groove 36 to the midsole and/or the secondary element80, generally positioned transverse to one or more channels 60 in thesole 80.

With the barrier element 70, and where included, the secondary elements80 in place in the groove, the outsole 40 can be adhered to the midsole30. In so doing, the outsole 40 as illustrated can complete the channels60 on the underside of the midsole 30. With the midsole and outsolejoined with one another, the sole 80 is adhered or cemented to the upper20.

With the sole 80 joined with the upper, the finished footwear 10 canundergo a number of conventional finishing operations. For example, themidsole 30 and outsole 40 and other parts thereof can be trimmed andshaped. The upper 20 can be clean, polished and treated as desired.

IV. First Alternative Embodiment

A first alternative embodiment of the footwear is illustrated in FIG.10. This footwear is similar to the embodiment described above withseveral exceptions. For example, the sole 280 generally does not includea heel wedge. Instead, it includes a structure having a tray-like oru-shaped barrier element 270 positioned adjacent a secondary element280. The secondary element 280 can include the mesh screen as describedabove to prevent debris from entering the footwear. The sole 280 canalso define multiple sets of channels 260 and 266. The channel 260includes an opening 261 defined in a sidewall 231 of the midsole 230.The sole 280 also can include a second larger channel 266 that extendsthrough the outsole 240 as well as a portion of the midsole 230. Thelower portion of the barrier element 270 facing the channel 266 can beadjacent a mesh 286 included in the secondary element 280. Optionally,the mesh 286 can be a completely separate element. Indeed, the mesh 286can be joined with a portion of the barrier element 270 as desired.

This construction operates in a similar manner to that of the embodimentdescribed above, with air flowing from the exterior 110 into and outfrom the interior 120 through the channels 260 and 266 as shown with thearrows. Again, as explained above, the barrier element can enable theair flow to pass directly through the element and/or around gaps betweenthe element and another component of the footwear. When wetted, thebarrier element operates to restrict flow through the channels 266 and260, and generally to prevent the flow of water into the interior 120 ofthe footwear.

V. Second Alternative Embodiment

A second alternative embodiment of the footwear 310 is generallyillustrated in FIG. 11. This embodiment is similar to the embodimentsdescribed above with several exceptions. For example, instead of havingchannels that open through the exterior sidewalls 331 of the midsole330, this construction can include a large channel 366 opening throughthe outsole 340 and the lower portion of the midsole 330 to theenvironment. Like the first alternative embodiment described above, abarrier element 370 can be positioned adjacent a secondary element 380.A mesh screen 386 can be positioned immediately adjacent the barrierelement to prevent dirt and debris from entering the barrier elementand/or the interior 120 of the footwear. The barrier element 370 can beof a generally planar configuration, in the form of a widened strip orsheet, extending across the channel 366. When dry, the barrier elementallows air to travel through the channel 366 from the exterior 110 intoand out from the interior 120 of the footwear. When wet, the barrierelement 370 operates in the same manner as described in the embodimentsabove, generally restricting liquid, such as water, from passing aroundand/or through the barrier element. In turn, this provides a waterbarrier to keep the interior 120 of the footwear relatively dry.

VI. Third Alternative Embodiment

FIG. 12 generally illustrates a third alternative embodiment of thefootwear 410, which is similar to the above embodiments with severalexceptions. For example, the midsole 430 and the sole 480 in general candefine channels 460 extending inwardly from the sidewalls 431. Thesechannels 431 can be in fluid communication with the interior 120 of thefootwear 410. A chamber 435 can form a portion of the channels 460 asdesired. The barrier element 470 can be positioned within the sidewalls431. These barrier elements can be of a special configuration and canhave a desired geometric cross section, for example, a circular, square,elliptical or other polygonal cross section, that generally matches thegeometric cross section of the portion of the channels 460 within whichthey are positioned. A mesh screen 486 can be embedded in the materialof the midsole generally between the opening 461 of the channels and thebarrier element 470. The barrier element also can include an enlargedinternal passageway 471. The added passageway 471 can increase air flowinto and out from the footwear and air circulation in general. A gap 477can be formed around the perimeter of the barrier element 470. Thebarrier element 470 can be spot glued with adhesive 479 within thechannel 460.

Air can flow directly through the barrier element 470 through itsinternal passage 471 and/or around the barrier element through the gap477 into and out from the interior 120 of the footwear. When subjectedto water, however, the barrier element 470 can act as a valve and swellfrom a reduced mode to a swelled mode, in which it closes the gap 477adjacent the element 470, as well as the internal passageway 471extending through the element 470. In turn, water is restricted fromflowing through or around the gap. In effect, the barrier element atleast partially closes off the channel to prevent water from passingfrom the exterior 110 into the interior 120 of the footwear. If desired,a heel button or other cushion (not shown) can be positioned within thecompartment 435. Optionally, however, the cushion can be dimensioned sothat it does not completely close off the fluid communication betweenthe openings 439 in the upper plate 434 of the midsole and the channels460.

VII. Fourth Alternative Embodiment

A fourth alternative embodiment of the footwear 510 is generallyillustrated in FIGS. 13 and 14. This embodiment is similar to theembodiments described above with several exceptions. For example, theoperation and construction of the barrier elements 570 differs from thatof the above embodiments. This embodiment includes channels 560 that arein fluid communication with a chamber 535 which is further incommunication with openings 539 in the sole 590 that open to theinterior 120 of the footwear 510. As shown, the sole 590 includes achamber 535 defined in the midsole 530. This chamber 535 is in fluidcommunication with the channels 560. One or more screens 586 aredisposed in the channel and/or chamber 535. The barrier elements 570 canbe constructed of the same materials described in the embodiments above.Joined with these barrier elements 570 are sealing elements 505. Thesealing elements 505 can be constructed from rubber, polymers, nylon,EVA, PVC, or a variety of other materials.

The sealing elements 505 are generally aligned with the holes 539 thatlead to the interior 120 of the footwear. The sealing elements 505generally include a base 506 that extends across a portion of theindividual barrier elements 570. The base 505 can be joined with therespective barrier element 570 in a variety of manners, for example, bycement, adhesives, stitching or other fastening mechanisms. The base canfurther optionally include a guide element 507, which extends upwardlytoward the opening 539 with which the respective sealing element 505 isaligned. In general, the guiding element 507 can operate to generallycenter the base 506 relative to the opening 509. Of course, the guidingelement 507 can be absent from the construction if desired.

Although shown as multiple separate sealing elements 505 (as illustratedthere are three sealing elements), multiple sealing elements can becombined together as one sealing element, and can extend across multipleopenings 539 heading to the interior 120 of the footwear 510. Further,although shown as three separate barrier elements 570, the barrierelements 570 can be combined into a single barrier element 571 (shown inphantom lines) with the respective sealing elements 505 joined with thatsingle barrier element 571.

The sole 590 can include a secondary openings 583 defined in a secondaryelement 580. These secondary openings 583 generally open to a largechannel 566 defined through the lower portion of the sole 590, and inparticular the lower portion of the midsole 530 and outsole 540.

Referring to FIG. 13, each of the individual barrier elements 570 can bejoined with the secondary element 580 and held in place and/or trappedby a seat 589. Of course, the barrier element can be glued, adhered orotherwise fastened at its lower portion to the seat 589, or generally tothe surface of the secondary element 580 facing the chamber 535.

In operation, like the above embodiments, the barrier element 570generally enables air to travel through the channels 560 through theopenings 539 in the sole 590 into and out from the interior 120 of thefootwear 110. For example, air can flow from the exterior 110 throughthe channels 560 into the compartment 535 through the opening 539 aswell as through the mesh 527 into the interior 120 of the upper. Air mayflow in the opposite direction as well. In general, the openings 539, aswell as the chamber 535 can be considered part of the channel 560, asthese elements are all in fluid communication with one another.Optionally, air also can flow through the lower channel 566, through theopenings 583, the chamber 535, the openings 539, through the mesh 527,and into or out from the interior 120.

As illustrated in FIG. 13, when dry, the barrier elements 370 are in areduced mode. Accordingly, air can flow past the sealing elements 505into or out from the interior 120 of the footwear and through therespective channels 560 and 566. When, however, the barrier elements aresubjected to liquids or water, they expand. Accordingly, each individualbarrier element 570 increases in dimension, which causes the barrierelement to urge the sealing element 505 toward the area surrounding therespective holes 539 that lead to the interior 120 of the upper 520.Expansion continues until the barrier elements 570 press the sealingelements 505 into sealing engagement with the surface 538 adjacent theholes 539. The guiding elements 505, where included, generally guide thesealing element, aligning the base with the holes 539 so that the baseengages the surface 538 to seal the holes. Accordingly, with the holes539 sealed by the respective sealing elements 505, water is restricted,and in some cases completely prevented, from entering the interior 120through the holes 539. Of course, other combinations and variations ofthe constructions for the barrier elements and sealing elements can besubstituted for that shown in FIGS. 13 and 14.

Generally speaking, the barrier element undergoes a phase change, whichin turn causes the barrier element to expand, pushing the sealingelement 505 into sealing engagement with the surface 538, therebyeffectively closing off the channel 560 which leads to the interior 120.This restricts the flow of water from the exterior 110 to the interior120 of the upper 520 when the footwear is subject to water as shown, forexample, in FIG. 14.

The above description is that of the current embodiments of theinvention. Various alterations and changes can be made without departingfrom the spirit and broader aspects of the invention as defined in theappended claims, which are to be interpreted in accordance with theprinciples of patent law including the doctrine of equivalents. Anyreference to claim elements in the singular, for example, using thearticles “a,” “an,” “the” or “said,” is not to be construed as limitingthe element to the singular.

1. A footwear comprising: an upper including an interior in which awearer's foot is positioned; a sole joined with the upper, the soledefining a channel that extends from an exterior of the footwear andthat is in fluid communication with the interior of the upper, thechannel adapted to allow air from the exterior of the footwear to travelto the interior of the upper; and a barrier element at least partiallypositioned in the channel, the barrier element being a non-woven fabricincluding a water absorbent polymer that expands in size when exposed towater, wherein the barrier element undergoes a phase change to at leastpartially close the channel when exposed to water, thereby restricting aflow of water from the exterior of the footwear to the interior of theupper.
 2. The footwear of claim 1 wherein the sole includes a midsoleand an outsole, wherein the channel is defined at least partially in themidsole, but not in the outsole.
 3. The footwear of claim 2 wherein themidsole defines a chamber in fluid communication with the channel. 4.The footwear of claim 3 wherein the midsole defines a hole above thechamber, the hole being in fluid communication with the interior of theupper, the hole and chamber forming a portion of the channel.
 5. Thefootwear of claim 4 wherein the upper includes a waterproofing membraneto restrict water from entering the interior of the upper, thewaterproofing membrane terminating adjacent the hole so that air cancirculate from the interior of the upper, through the hole.
 6. Thefootwear of claim 1 comprising a groove defined in the sole andtransverse to the channel, wherein the barrier element is positioned inthe groove, and is transverse to the channel.
 7. The footwear of claim 1comprising a waterproofing membrane joined with the upper, thewaterproofing membrane defining a first hole atop the upper and a secondhole adjacent the sole, the second hole being in fluid communicationwith the channel so that air can flow through the channel and hole intothe interior of the upper.
 8. The footwear of claim 1 wherein thebarrier element is positioned adjacent a secondary element, thesecondary element transverse to the channel, the secondary element andthe barrier element defining a gap therebetween when the barrier elementis dry, the barrier element adapted to swell into the gap when thebarrier element is wetted with water so as to close at least a portionof the gap and to restrict water from entering the interior of the upperthrough the gap.
 9. The footwear of claim 1 comprising a sealing elementjoined with the barrier element, the sealing element positioned adjacenta hole defined by the sole, the hole wherein the barrier element pushesthe sealing element, forming a portion of the channel, into engagementwith the sole to restrict the flow of water through the hole.
 10. Afootwear comprising: an upper including an interior in which a wearer'sfoot is positioned; a sole joined with the upper; a channel defined byat least one of the upper and the sole, the channel extending from anexterior of the footwear and in fluid communication with the interior ofthe upper; and a barrier element in fluid communication with thechannel, the barrier element including a phase change material thatswells to at least partially close the channel when exposed to water,thereby restricting a flow of water from the exterior of the footwear tothe interior of the upper, whereby the interior of the upper remainsrelatively dry when the exterior of the footwear is subjected to water.11. The footwear of claim 10 wherein the sole includes a midsole and anoutsole, wherein the channel is defined by the midsole and the outsole.12. The footwear of claim 10 comprising a mesh screen extending acrossthe channel, wherein the barrier element is located between the meshscreen and the interior of the upper.
 13. The footwear of claim 12wherein the mesh screen is included in a base, wherein the barrierelement is located adjacent at least one of the base and the mesh screenwith a gap formed at least partially between the barrier element and atleast one of the base and the mesh screen, wherein the mesh screenallows water to pass through the mesh screen to contact the barrierelement, wherein the barrier element swells when contacted with thewater that passes through the mesh screen to at least partially closethe gap.
 14. The footwear of claim 10 comprising a waterproofingmembrane defining an opening adjacent the sole in fluid communicationwith the channel, through which air can flow from the exterior of thefootwear.
 15. A footwear comprising an upper joined with a sole, atleast one of the upper and sole defining a channel that allows air tocirculate to the upper through the channel, the channel including aphase change material that swells when subjected to water disposedtherein, wherein the phase change material acts as a valve to restrictthe flow of water into the upper through the channel when the footwearis subjected to water.
 16. The footwear of claim 15 wherein the soleincludes a plurality of the channels, wherein the phase change materialis in the form of a strip of a water absorbing non-woven cloth includinga water absorbing polymer, wherein the strip is positioned transverselyacross the plurality of channels.
 17. The footwear of claim 15comprising a sealing element joined with the phase change material,wherein the sealing element is positioned adjacent a portion of thechannel when the footwear is dry, wherein the barrier element moves thesealing element into engagement with at least one of the sole, thechannel and the upper, to seal the channel and restrict the flow ofwater into the upper through the channel when the footwear is subjectedto water.
 18. The footwear of claim 15 wherein the sole defines thechannel, wherein the upper includes a waterproof membrane, wherein thewaterproof membrane defines an opening in fluid communication with thechannel, wherein the opening is adapted to allow air to enter the upperfrom the sole.
 19. The footwear of claim 18 wherein the sole defines agroove transverse to the channel, wherein the barrier element is in theform of a strip, wherein the strip is positioned in the groove with thebarrier element being transverse to the channel.
 20. The footwear ofclaim 19 comprising a mesh screen located between the barrier elementand the exterior of the footwear.
 21. The footwear of claim 15 whereinthe sole includes a midsole having an exterior, visible side, whereinthe channel is defined in the midsole and includes an opening defined inthe exterior, visible side, wherein the barrier element is locateddistal from the opening in the channel.
 22. The footwear of claim 15wherein the phase change material is a water absorbent polymer includedin a non-woven sheet.